I picked up a nice Marples oval bolstered mortise chisel a while back, and after using it on one project the handle split. I had not re-handled a tang chisel, so it was a new experience for me. Unfortunately, I did not take pictures of the process, but I will explain what I did and I have a picture of the finished product.
And here it is next to the original handle that is cracked. I tried to use the original as a model for my new handle. Mine actually fits at the bolster slightly better and is about a 1/2 or so longer.
The first step was to saw the blank to width out of 8/4 ash. A square section worked nicely. Next, I had to flatten an edge and square an adjacent edge to it. Then, I could square off the end of the blank. On the square end, mark the center of the blank. Then I drilled a pilot hole for the tang. Then I measured the tang at the bolster and marked the top of the blank. I then attacked it with chisels to finish up the tang mortise. An 1/8 firmer style chisel is almost a must here.
The blank should fit almost all the way on the tang, except maybe 1/4 inch of space between the blank and the bolster, leave less space for harder woods. Then hammer it home with a mallet. Then I shaped the handle. I used a spokeshave, a block plane, a rasp, a file and some sandpaper. I finished it off with a few coats of tung oil. I have used it on a few projects since making the handle, and I am very pleased.
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